Engineered wood products and an introduction to timber structural systems

Engineered wood products and an introduction to timber structural systems There are limitations on the maximum cross-sectional size and lengths of sawn timber that can be used as a structural component due to the availability of log sizes and the presence of naturally occurring defects in the timber (see Timber Engineering Notebook No. 1). These defects can be cut out and the timber reconstituted using engineered wood techniques such as finger jointing (Figure 1) to create longer lengths of timber of an assured strength grade, or laminating to form a homogeneous timber section. Combinations of timber or laminated sections with different materials such as wood-based boards or metal elements are used to create engineered wood products (EWPs) whose maximum size is limited only by manufacturing, handling and transportation constraints. In addition to engineered wood products, there are reconstituted board products which comprise smaller wood-based strands and fibres re-formed into panel products. These have structural applications but are also used extensively in the furniture-making and packaging industries. Types of timber structural systems and their applications are also introduced in this Notebook. Engineered wood products EWPs including glued laminated timber, finger joints, plywood, stressed skin panels, mechanically and adhesive bonded web beams and connectored and nail plated trusses, have been in existence for at least 40 years. Recently, there have been significant developments in the range of EWPs for structural applications with materials such as laminated veneer lumber (LVL), parallel strand lumber (PSL), laminated strand lumber (LSL), prefabricated I-beams, metal web joists and massive or cross-laminated timber (CLT) becoming more widely available. These EWPs are typically manufactured by adhesively laminating together smaller softwood sections or laminates (e.g. glulam and CLT) or veneers or strands of timber (e.g. LVL, LSL and PSL). The varying performance of EWPs is influenced by the size of wood component used in the product. At one end of the spectrum smaller sections of timber are laminated and finger jointed to form sections of glulam, whilst at the other end, reconstituted board products such as oriented strand boards (OSBs) and medium density fibre boards (MDFs) use small wood strands or fibres bonded together (Table 1). Figure 1 Finger jointing of timber Table 1: Fibre size and beam types for timber products Timber Engineered wood products (EWPs) Reconstituted board products Sawn timber sections As cut from the tree Finger jointed lengths of timber Fabricated from smaller lengths of timber to form a longer element length Glulam and CLT Small sections typically 25-45mm thick glued together to form a bigger beam or slab section Veneers e.g. LVL or plywood Typically 2-4mm thick wood glued together to form sections both boards and beams Strands e.g. OSB wood slices Glued together to form sections both boards and beams Wood fibres Bonded to form sections more typically used for board products than beams e.g. particleboards and fibreboards DECREASING SIZE OF ORIGINAL WOOD MATERIAL

2 Softwood chords Figure 3 Use of I joists for a floor structure Plywood or OSB web Profiled metal webs Timber or LVL flange Figure 4 Open web joist Plywood Plywood is a flat panel made by bonding together, under pressure, a number of thin layers of veneers (or plies). Plywood was the first type of EWP to be widely available. The structural properties and strength of plywood depend mainly on the number, thickness, species and orientation of the plies. The structural grade plywoods that are commonly used in the UK construction industry are: Thin webbed joists (I joists) I joists (Figure 2) are an EWP manufactured with flanges made from softwood or LVL with glued thin webs generally made from OSB, fibreboard or plywood. I joists can be used to resist either flexural or axial loads or a combination of both (Figure 3). Metal web or open web joist Open web joists are shallow parallel-chord trusses manufactured using similar techniques to that used for trussed rafters comprising a member with flanges (or chords) usually made from softwood and with metal or timber strutting to form the webs (Figure 4). American construction and industrial plywood Canadian softwood plywood Finnish birch-faced, birch and conifer plywoods. Birch plywood gives a good fair-faced finish and is readily persuaded into curved profiles Swedish softwood plywood Plywoods are typically used for roof and floor decking applications and for wall sheathing boards. Plywood for structural applications should be specified as having exterior glue bond to BS EN 314-2 and veneers in compliance with BS EN 636:2003. This replaces the previous definition for the plywood of WBP exterior grade where WBP describes the properties of the adhesive and exterior grade describes the durability of the outer veneers. The chords (and webs where timber webs are used) are generally planed softwood graded in accordance with BS EN 14081-1. The strength class of the timber is usually C27 in accordance with BS EN 338:2009 or TR26 (whose characteristic strength values are equal to that of C27 but whose characteristic stiffness values are taken from BS5268-2:2002). The depth of the chords is generally 47mm and their widths range from 72mm to 145mm. Metal webs are typically profiled, nominal 1mm galvanised light gauge steel with a zinc coating specification of Z275. The characteristic strength and stiffness values for plywood for use in structural design are contained in BS EN 12369-2:2004. Open web joists are principally used as a roof or floor joist element. They are often preferred to I-joists as they allow a combined services and structural zone. LVL is often used for high load applications to resist either flexural or axial loads or a combination of both. It can provide both panels and beam/column elements. Laminated veneer lumber Laminated veneer lumber (LVL) is a structural member manufactured by bonding together thin vertical softwood veneers with their grain parallel to the longitudinal axis of the section, under heat and pressure. In some cases cross grain veneers are incorporated to improve dimensional stability. The requirements for LVL are contained in product standard BS EN 14374:2004. 2

Laminated strand lumber Laminated strand lumber (LSL) is a structural member made by cutting long thin strands approximately 300mm long and 0.8mm - 1.3mm thick directly from de-barked logs. The strands are blended, coated with adhesive and oriented so that they are essentially parallel to the longitudinal axis of the section before being reformed by steam-injection pressing into a solid section. LSL is used in similar applications to LVL. Parallel strand lumber Parallel strand lumber (PSL) is a structural member made by cutting long thin strands (typically 3.2mm thick, 20mm wide and up to 3.0m long) from timber veneers. The strands are oriented so that they are essentially parallel to the longitudinal axis of the section before being coated with adhesive and fed into a continuous press and microwave-cured. PSL is used in similar applications to LVL. Figure 5 Connections in curved,vertically laminated glulam Figure 6 Cross laminated timber Table 2: Characteristic strength, stiffness and density properties for some EWPs LSL and PSL have recently become less widely available in the UK due to a preference for LVL and supply chain considerations. Glued laminated timber Glued laminated timber (glulam) is a structural member made by gluing together a number of graded timber laminations with their grain parallel to the longitudinal axis of the section. Members can be straight or curved, horizontally or vertically laminated and can be used to create a variety of structural forms (Figure 5). Laminations are typically 25mm or 45mm thick but smaller laminations may be necessary where tightly curved or vertically laminated sections are required. The requirements for the manufacture of glulam are contained in product standard BS EN 14080: 2013. Cross laminated timber Cross laminated timber (CLT) is a structural timber product with a minimum of three cross-bonded layers of timber, of thickness 6mm to 45mm, strength graded to BS EN 14081-1:2005 and glued together in a press which applies pressure over the entire surface area of the panel. CLT panels typically have an odd number of layers (3,5,7,9) which may be of differing thicknesses but which are arranged symmetrically around the middle layer with adjacent layers having their grain direction at right angles to one another (Figure 6). The structural benefits of CLT over conventional softwood wall framing and joisted floor constructions, include: large axial and flexural load-bearing capacity when used as a wall or slab high in-plane shear strength when used as a shear wall fire resistance characteristics for exposed applications superior acoustic properties Due to its arrangement as a panel rather than a framed construction comprising discrete loadbearing elements, CLT also distributes concentrated loads as line loads at foundation level. A variant of CLT developed in Germany in the 1970s is Brettstapel or massive timber, which is the term commonly used for solid timber construction that does not generally use glue or nails. Fabricated from softwood timber posts connected with hardwood timber dowels, the system works by using dowels with a moisture content lower than that of the posts. Over time, the dowels expand to achieve moisture equilibrium, thus locking the posts together and creating a structural load-bearing panel system. CLT should be designed using the principles given in BS EN 1995-1-1 and -1-2 together with data from the manufacturer of the product. Table 2 illustrates the properties of a variety of EWPs. Reconstituted wood-based board products Reconstituted board products are typically manufactured by combining smaller wood strands or fibres with adhesive. There is a structural penalty when timber is modified from a sawn product to small strands and fibres used in board products, as the effects of creep increase as the amount of glue used to join the smaller wood elements increases. The design of reconstituted timber board materials takes the resulting reduced performances into account by the use of relatively low values for the factor kmod in BS EN 1995-1-1 Table 3.1 for OSB, particleboards and fibreboards. Oriented strand board Oriented strand board (OSB) is a multilayer board made from strands of wood sliced from small diameter timber logs and bonded together with an exterior grade adhesive, under heat and pressure. OSB is manufactured in various grades with improving resistance to the effects of moisture. The minimum grade that should be used for 3

Table 3: Summary of timber, engineered wood and board products and their structural applications 4

Figure 7 Comparison of modulus of elasticity (E) and associated variation with various timber grades and structural timber composites Figure 8 Scunthorpe Sports Academy: example of glulam gridshell roof structural applications is OSB/3 as given in BS EN 300:1997. OSB is commonly used as a structural sub deck material for floors and roofs and as a sheathing material for walls. It is also used for composite constructions such as I joist webs and structural insulated panels (SIPs). Particleboard and fibre composites There are a number of different board materials made from particle and fibre composites including fibreboards, tempered hardboard, cement-bonded particleboard and wood chipboard. The most common for structural applications is chipboard, which is made from small particles of wood and binder. Chipboards are classified as grades P1-P7 in BS EN 312:2003 depending on their intended use. The minimum grade that should be used for structural applications is P5 which is a moisture-resistant grade. The characteristic strength and stiffness values for OSB, particleboards and fibreboards for use in structural design are contained in BS EN 12369-1:2001. Table 3 shows the range of timber and EWPs available, together with their typical applications. Advantages of EWPs as structural materials Use of waste timber Timber can be recycled and turned into strands and fibres and reconstituted into an engineered wood product. Enhanced strength and stiffness By building up a structural section from a number of smaller elements it is possible to reduce the variability inherent in natural timber, thereby improving the strength and stiffness of the composite section. This is illustrated in Figure 7 which shows the mean and 5th percentile modulus of elasticity parallel to the grain associated with a range of softwoods, hardwoods and structural timber composites. The figure shows that composites have better stiffness properties than the natural sawn sections from which they are composed. Increased size and scope of application Engineered timber structures incorporate factory produced components where the constraints on length and section may be determined only by manufacturing, handling and transportation considerations rather than the constraints set by the size of log available. It is therefore possible to extend the range of timber engineering possibilities to large span and tall structures. Reduced moisture content The production requirements for certain EWPs may call for low moisture content e.g. gluing, which can result in lower movement upon drying out in service. However, in some cases (e.g. OSBs) the moisture content of the product following manufacture is lower than will be experienced during the construction phase, which can lead to problems due to dimensional changes of the product in humid environments. Dimensional consistency Engineered wood products disperse the natural defects inherent in solid timber and are manufactured to controlled tolerances. As a result, their dimensional consistency is significantly improved. This can be beneficial where tight tolerances may be required e.g. at connections. More regular joist depths also result in flatter floor structures than would be possible with sawn timber joists; thus avoiding some of the problems that can be associated with small variations in joist depth such as nail squeak. Ease of installing services and ease of handling Service runs for mechanical and electrical infrastructure can easily be installed through open-web joists and, to a lesser extent, through I joists. I joists and open web joists in particular are lighter in weight than equivalent solid timber sections and are therefore easier to handle. Types of timber structures Structural methods have been developed, incorporating EWPs, to provide timber structures which achieve a particular function with satisfying aesthetic form and performance e.g. timber gridshells and stressed skin panel roofs (Figure 8). Portal frames and beam and post structures Large open plan structures can be created by using portal frames and beam and post structures constructed from engineered wood products. Platform frame construction Methods of construction such as platform frame construction enable the construction of multi-storey timber frame structures for buildings which have a cellular arrangement of rooms and where internal loadbearing walls can be utilised. 5

Table 4: Types of timber structural systems and their applications Trussed rafters The modern trussed rafter roof is an engineered timber structure that has evolved in form over the past 40 years, but most commonly adopts the use of softwood timber tension and compression members connected in a single plane by punched metal plate fasteners, manufactured from galvanised mild steel. Structural insulated panels Other structural systems such as structural insulated panels (SIPs) are composite members which use a core of rigid insulation, not only to provide a u-value for a building s thermal envelope, but also to form a longitudinal shear connection between plywood or OSB face layers; thus enabling it to act as a structural panel. Table 4 provides a brief description of the types and scope of engineered timber structures that can be designed to provide structurally efficient and aesthetically appealing structures for a wide variety of building uses. These and other structural methods will be investigated in more depth in subsequent articles in this series. 6

Design Eurocode 5 has provided opportunities for UK designers to use timber for new applications that should give economic solutions, particularly as the code makes provision for the use of new materials, such as engineered wood products and new efficient jointing techniques. The code encourages engineers to gain a greater understanding of timber which will lead to more efficient and innovative designs for engineered timber structures. Structural forms and detailing, together with examples of calculations for structural timber to Eurocode 5, will be discussed in future articles. Limitations In addition to the structural strength and stiffness aspects of timber engineering there are other considerations which affect wholebuilding performance and must be considered. These include: Timber shrinkage and differential movement Design for robustness Architectural detailing including detailing for durability Fire during construction and service Workmanship and maintenance As with structural form/detailing etc., these topics will be explored in more depth, later in the series. RELEVANT CODES OF PRACTISE BS 5268-2:2002 Structural use of timber Part 2: Code of practice for permissible stress design, materials and workmanship BS EN 300:1997 Oriented Strand Boards (OSB) Definitions, classification and specifications BS EN 312:2003 Particleboards - Specifications BS EN 338:2009 Structural timber - Strength classes BS EN 636:2003 Plywood Specifications BS EN 1995-1-1 Eurocode 5: Design of Timber Structures Part 1-1: General Common rules and rules for buildings DEFINITIONS Engineered wood products - reconstituted wood-based products which may be formed from homogenous wood-based material; for example glulam or non-homogenous products to form a composite material e.g. I joists. Composites - an assembly of engineered or naturally occurring materials made from more than one constituent part, which work together structurally. REFERENCES AND FURTHER READING Porteus J. and Kermani A. (2008) Structural Timber Design to Eurocode 5 Chichester: John Wiley & Sons The Institution of Structural Engineers/TRADA (2007) Manual for the design of timber building structures to Eurocode 5 London: ISE/TRADA UKTFA (2007) Engineered Wood Products Code of Practice [Online] Available at: https://jji-joists.s3.amazonaws.com/ewp-cop.pdf (Accessed: February 2013) Lancashire R. and Taylor L. (2011) Timber Frame Construction (5th ed.) High Wycombe: TRADA TRADA (2011) Wood Information Sheet: 1-6 Glued laminated timber - an introduction High Wycombe: TRADA TRADA (2011) Wood Information Sheet: 2/3-61 Cross-laminated timber - introduction for specifiers High Wycombe: TRADA TRADA (2011) Wood Information Sheet: 2/3-23 Introduction to woodbased panel products High Wycombe: TRADA TRADA (2009) Guidance Document 10 (GD10) Cross-laminated Timber (Eurocode 5) Design Guide for Project Feasibility High Wycombe: TRADA Ozelton E.C. and Baird J.A. (2006) Timber Designers Manual (3rd ed.) Chichester: Wiley-Blackwell British Standards Institution (2012) Concise Eurocodes: Design of Timber Structures BS EN 1995-1-1: Eurocode 5 London: BSI Herzog T. et. al (2004) Timber Construction Manual Birkhauser Architecture UK National Annex to Eurocode 5: BS EN 1995-1-1: Design of Timber Structures Part 1-1: General Common rules and rules for buildings PD 6693-1:2012 UK Non-Contradictory Complementary Information (NCCI) to Eurocode 5: Design of timber structures BS EN 12369-1:2001 Wood-based panels Characteristic values for Structural Design: Part 1: OSB, Particleboards and Fibreboards BS EN 12369-2:2004 Wood-based panels Characteristic values for Structural Design: Part 2: Plywood BS EN 14080:2013 Timber structures Glued laminated timber Requirements The Structural Timber Association represents over 85% of the UK s timber structural frame supply industry and is a trade organisation that provides business and technical support to the industry. The Association provides peer reviewed outputs on subjects related to the timber industry such as health and safety, fabric and technical performance, fire safety, promotion and training. These documents and other information are available at /information-centre/technical-library BS EN 14081-1:2005 Timber Structures Strength graded structural timber with rectangular cross-section. General requirements BS EN 14374:2004 Timber structures. Structural laminated veneer lumber. Requirements 7